Insulating and acoustical panel structure



June 13, 1967 J. P. ROBINSON 3,324,967

INSULATING AND ACOUSTICAL PANEL STRUCTURE Filed Sept. 17, 1964 2Sheets-Sheet 1 INVENTOR. JAMES 1 1 ROBINSON M/WL KW M A TTORN E Y3 June13, 1967 J. P. ROBINSON INSULATING AND ACOUSTICAL PANEL STRUCTURE 2SheetsSheet 2 Filed Sept. 17, 1964 INVENTOR. JAMES R Rosmsou ATTORNEYSbody of fibrous material consisting of two United States Fatent Cflice3,324,967 Patented June 13, 1967 3,324,967 INSULATING AND ACOUSTICALPANEL STRUCTURE James P. Robinson, 11118 Greenwich Ave, Cleveland, Ohio44105 Filed Sept. 17, 1964, Ser. No. 397,148 25 Claims. (Cl. 18133) Thisinvention relates to an insulating and acoustical panel structure andparticularly to such a structure wherein the panels may be adhered orsuspended from a ceiling.

It is an object of this invention to provide an inexpensive, attractiveand efficient insulating and acoustical panel structure which is made oflow-cost materials, requires minimum maintenance, and may be easilyapplied either by the use of adhesive or fastening clips.

It is a further object of this invention to provide a novel ceiling andpanel structure.

It is a further object of this invention to provide a novel mountingstructure.

In the drawings:

FIG. 1 is a perspective view of the panel embodying the invention.

FIG. 2 is a fragmentary sectional view on an enlarged scale taken alongthe line 2 2 in FIG. 1.

FIG. 3 is a fragmentary bottom perspective view of the panel shown inFIG. 1.

FIG. 4 is a fragmentary perspective view of the top section of thepanel.

FIG. 5 is a fragmentary vertical section through a ceiling having thepanels embodying the invention adhered thereto.

FIG.6 is a fragmentary vertical section of a ceiling having the panelsembodying the invention suspended therefrom.

FIG. 7 is a fragmentary perspective view of a mounting panel utilized inFIG. 6.

Referring to FIGS. 1-4, the insulating and acoustical panel 10 embodyingthe invention comprises a hollow telescoping sections 11, 12 which aregenerally rectangular. Top section 11 includes a generally flat top wall13 and an integral peripheral side wall 14. The major portion of topwall 13 is depressed relative to the upper edge of the side wall 14 todefine a well or recess 15 around the top section 11.

The second or bottom section 12 includes a substantially fiat bottomwall 16 and an integral peripheral side wall 17 telescoped over aportion of the side wall 14 of the upper section 11. Side wall 17 isconnected to bottom wall 16 by a bevelled portion 13.

Each of the side walls 14, 17 is provided with openings 19, 20 in theoverlapping portions thereof which are of small size and adhesive 21 isutilized to fasten the side walls 14, 17 to one another, the adhesivepenetrating through the openings 19, 20 to provide an eflicient lockingaction.

The outer surface of the top panel 11 is provided with a metallic layer22 which is applied by vacuum deposition and provides heat insulatingproperties. As shown in FIG. 2, the depthof the layer is greatlyexaggerated and may be on the order of one to two ten-thousandths of aninch.

A batt of sound and heat insulating material, preferably rock wool, isadhered to the top wall 13 by suitable adhesives such as an epoxyadhesive. The thickness of the batt 23 is such that a space 24 isprovided between the inner surface of the bottom wall 16 and the batt23. Satisfactory results may be achieved by utilizing a rock wool havinga density of about six pounds per cubic foot. A glass fiber batt mayalso be used having a density on the order of about one pound per cubicfoot.

The bottom wall 16 is provided with spaced openings 25 that providepaths for passage of sound within the space 24 to providesound-absorbing properties.

The sections 11, 12 are preferably made of a fibrous material,preferably wood cellulose fiber. The sections 11, 12 are molded inaccordance with well-known techniques for molding fibrous materials.Preferably, a mixture of cellulose fibers, asbestos fibers, and gypsumis formed into a slurry and molded on a form by a vacuum method.Suitable dyes are added to the slurry molding in order to produce thedesired appearance of the panel. In addition, a resin is added to theslurry to provide wet strength. A satisfactory resin comprises amelamine-formaldehyde resin such as Parez resin 607 made by The AmericanCyanamid Company.

After molding, the sections are placed upon forms with the externalsurfaces exposed and passed through drying ovens. After the sections 11,12 have been substantially dried and while they are still on the forms,they are sprayed with a suitable flame retardant and again dried. Asatisfactory flame retardant may be of the ammonium sulfamate type suchas CM flame retardant made by E. I. du Pont de Nemours and Company ofWilmington, Del.

After substantial drying, the sections 11, 12 while still on the formsare treated with a grease and water inhibitor and again dried. Asatisfatcory material comprises FC- 805 which is a water soluble fluorocomposition made by Minnesota Mining and Manuafcturing Company of St.Paul, Minn. Finally, the sections 11, 12 are dried. If desired, a thintransparent film of polyethylene may be applied by spraying.

The outer surface of the bottom wall 16 may be em bossed during formingor may be otherwise decorated to produce any desirable aestheticeffects.

The panels may be applied to a ceiling either by the use of adhesive ormounting clips.

As shown in FIG. 1, the top wall 13 of each panel in cludes raisedmolded portions '27 which define pockets 28 at the corners of the panelinto which portions 29 of adhesive can be deposited so that the panelcan be pressed upwardly against a ceiling (FIG. 5) to mount the panel inposition. The pocket 28 locates the adhesive properly for readyinstallation. In order to facilitate the adhesion of the adhesive to thetop wall '13, small openings 28a are provided through the bottom ofpocket 28.

Alternatively, each side wall 14 is provided with spaced longitudinallyextending slots 31 so that the panel can be suspended from the ceiling32 (FIG. 6). A mounting channel 33 having a flange 34 is fastened bynails 35 to the ceiling and has projecting tabs 36 which extend into theslots 31 to suspend the panels from the ceiling. At the side walls 37, amolding strip 38 fastened by nails 39 is used to hold the panels.

In order to insure proper alignment, the surface 40 (FIG. 2) of eachside wall 17 is preferably shaped as by grinding or shaving to form anaccurate surface which will abut to the adjacent surface. This surfacepreferably tapers upwardly and inwardly so that a sharp line 41 isprovided at the area of juncture between side Wall 17 and the bevelledportion 18.

A thin plastic coating 16a is provided on the outer surface of thebottom wall 16 and the bevelled portion 18 of the bottom section 12. Theplastic coating may comprise a thin transparent layer of polyethyleneapplied by spraying. The plastic coating 16a provides a base for furtherpainting as may be required either initially or after prolonged use ofthe panel, such as the use of vinyl latex paints. The panel may also beused in an air distribution system as a sound and filter element byproviding spaced holes in the top wall 13 of top section 11.

It can thus be seen that there has been provided an inexpensive,attractive and efficient insulating and acoustical panel structure whichis made of low cost material, requires minimum maintenance and may beeasily applied either by use of adhesive or fastening clips. The panelstructure results in a neat and aesthetic appearing ceiling.

I claim: 1. In an insulating and acoustical panel structure, thecombination comprising a hollow fibrous body including a top wall,bottom wall and peripheral side walls connecting the top and bottomwalls, a layer of fibrous insulating material fastened to the innersurface of the top wall,

said bottom wall being perforated,

a layer of metal applied by vacuum outer surface of the top wall,

and a thin plastic coating on bottom wall.

2. The combination set forth in claim 1 fibrous body comprises woodcellulose fibers which are treated with a flame inhibiting agent,asbestos and gypsum,

said fiber constituting the major portion of the material.

3. The combination set forth in claim 1 wherein said top wall includes aplurality of circumferentially spaced depressions adapted to receiveadhesive for adhering the panel to a ceiling or wall.

4. The combination set forth in claim 1 including a coloring dye in saidfibrous body.

5. The combination set forth dye comprises an aniline type.

6. The combination set forth in claim 1 plastic coating comprisespolyethylene.

7. The combination set forth in claim 1 including a vinyl latex paintcovering said plastic coating on the outer :surface of the bottom wall.

8. The combination set forth in claim 1 including a plurality of spacedholes in the top wall.

9. The combination set forth in claim 1 wherein said bottom wall isembossed.

10. The combination set forth in claim 1 wherein said layer ofinsulating material comprises rock wool.

11. In an insulating and acoustical panel structure, the combinationcomprising .a hollow body of fibrous material including a top wall,bottom wall and peripheral side walls connecting the top and bottomwalls,

:said top Wall being generally rectangular and having a plurality ofdepressions molded therein at the corners of said rectangle forreceiving adhesive whereby the panel can be attached to a ceiling orwall,

:a layer of insulating material fastened to the inner surface of the topwall,

:said bottom wall being perforated,

.a metallic layer vacuum deposited on the outer surface of the top wall,

and a plastic coating on the outer surface of the bottom wall.

12. In an insulating and acoustical panel structure, the

combination comprising a hollow body of fibrous material comprising afirst and second section,

said first section including a top wall and a peripheral side wall,

said second section including a bottom wall and a peripheral side wall,

said side walls of said first and second section being telescopedrelative to one another and fastened together,

a layer of insulating material fastened to the inner surface of the topwall of the first section,

said bottom wall of said second section being perforated,

a layer of metal vacuum deposited on the outer surface of the top wallof the first section,

deposition to the the outer surface of the wherein said body in claim 1wherein said wherein said and a plastic coating adhered to the outersurface of the bottom wall of the second section.

13. The combination set forth in claim 12 wherein said top wall of saidfirst section includes a plurality of molded raised portions thereindefining pockets for receiving adhesive whereby the panel may beadhesively secured to a ceiling or wall.

14. The combination set forth in claim 12 wherein each of said sidewalls of said first and second sections includes a plurality ofnonaligned holes therein and glue between said walls and in saidholesfastening said walls together.

15. The combination set forth in claim 12 wherein said side wall of saidsecond section is telescoped over the side wall of said first section.

16. The combination set forth in claim 15 wherein said side wall of saidsecond section is connected to said bottom wall of said second sectionby a bevelled portion.

17. The combination set forth in claim 16 wherein said side wall of saidsecond section is inclined inwardly towards the free edge of said sidewall from said bevelled portion thereby defining a sharp edge at thearea of juncture of said side wall of said second section and thebevelled portion.

18. The combination set forth in claim 12 wherein said side wall of saidfirst section is substantially greater in width than said side wall ofsaid second section,

said side wall of said first section having a plurality of spaced slotstherein adapted to receive mounting clips for fastening the panels to aceiling.

19. In an inuslating and acoustical panel structure, the combinationcomprising a hollow fibrous body including a top wall, bottom Wall andperipheral side walls connecting the top and bottom walls,

a layer of fibrous insulating material fastened to the inner surface ofthe top wall,

said bottom wall be perforated,

and a layer of metal applied by vacuum deposition to the outer surfaceof the top wall.

20. In an insulating and acoustical panel structure,

the combination comprising a hollow body of fibrous material including atop wall, bottom wall and peripheral side walls connecting the top andbottom walls,

said top wall being generally rectangular and having a plurality ofdepressions molded therein at the corners of said rectangle forreceiving adhesive whereby the panel can be attached to a ceiling orwall,

a layer of insulating material fastened to the inner surface of the topwall,

said bottom wall be perforated,

and a metallic layer vacuum deposited on the outer surface of the topwall.

21. In an insulating and acoustical panel structure,

the combination comprising a hollow body of fibrous material comprisinga first and second section,

said first section including a top wall and a peripheral side wall,

said second section including a bottom wall and a peripheral side wall,

said side walls of said first and second section being telescopedrelative to one another and fastened together,

a layer of insulating material fastened to the.inner surface of the topwall of the first section,

said bottom wall ofsaid second section being perforated,

a layer of metal vacuum deposited on the outer surface of the top wallof the first section,

said top wall of said first section including a plurality of moldedraised portions therein defining pockets for receiving adhesive wherebythe panel may be adhesively secured to a ceiling or wall, each of saidside walls of said first and second sections including a plurality ofnonaligned holes therein and glue between said walls and in said holesfastening said walls together, said side wall of said second sectionbeing telescoped over the side wall of said first section, said sidewall of said second section being connected to said bottom wall of saidsecond section by a bevelled portion, said side Wall of said secondsection being inclined inwardly towards the free edge of said side wallfrom said bevelled portion thereby defining a sharp edge at the area ofjuncture of said side Wall of said second section and the bevelledportion, said side wall of said first section being substantiallygreater in width than said side wall of said second section, said sideWall of said first section having a plurality of spaced slots thereinadapted to receive mounting clips for fastening the panels to a ceiling.22. In an insulating and acoustical panel structure, the combinationcomprising a hollow body of material including a top wall, bottom walland peripheral side walls connecting the top and bottom walls, said topwall being generally rectangular and having a plurality of depressionsmolded therein at the corners of said rectangle for receiving adhesivewhereby the panel can be attached to a ceiling or Wall, a layer ofinsulating material fastened to the inner surface of the top Wall, saidbottom Wall being perforated. 23. In an insulating and acoustical panelstructure, the combination comprising a hollow body of materialcomprising a first and second section, said first section including atop wall and a peripheral side wall, said second section including abottom wall and a peripheral side wall, said side walls of said firstand second section being telescoped relative to one another and fastenedtogether, said top wall of said first section having a major portionthereof spaced vertically below the periphery thereof, a layer ofinsulating material fastened to the inner surface of the top wall of thefirst section, the thickness of said layer being less than the spacebetween said major portion of the top wall of said first section andsaid bottom wall of said second section, said bottom wall of said secondsection being perforated. 24. In an insulating and acoustical panelstructure, the combination comprising a hollow body of materialcomprising a first and second section,

said first section including a top wall and a peripheral side wall,

said second section including a bottom wall and a peripheral side Wall,

said side Walls of said first and second section being telescopedrelative to one another and fastened together,

a layer of insulating material fastened to the inner surface of the topwall of the first section,

said bottom wall of said second section being perforated,

said top wall of said first section including a plurality of raisedportions therein defining pockets for receiving adhesive whereby thepanel may be adhesively secured to a ceiling or wall,

means for joining the side walls of said first and second sections,

said side wall of said second section being telescoped over the sideWall of said first section,

said side wall of said second section being connected to said bottomwall of said second section by a bevelled portion,

said side Wall of said second section being inclined inwardly towardsthe free edge of said side wall from said bevelled portion therebydefining a sharp edge at the area of juncture of said side wall of saidsecond section and the bevelled portion,

said side wall of said first section being substantially greater inwidth than said side wall of said second section,

said side wall of said first section having a plurality of spaced slotstherein adapted to receive mounting clips for fastening the panels to aceiling.

25. The combination set forth in claim 24 including a mounting paneladapted to be fastened to a ceiling including a flange,

downwardly projecting tabs,

said tabs having laterally extending clip portions engaging the slots inthe side Walls of the first section.

References Cited UNITED STATES PATENTS 1,785,507 12/1930 Weiss 181-331,998,422 4/ 1935 McNeil et a1 18133 2,007,374 7/1935 Kuehne 181---332,017,344 10/1935 Ellis 181-33 2,125,286 8/1938 Fletcher l81-332,326,763 8/1943 Crandell 18133 2,384,500 9/1945 Stoll l17107.12,796,636 6/1957 Heerwagen 181-33 2,951,771 9/1960 Butler 117-1263,204,380 9/ 1965 Smith et a1. 18133 FOREIGN PATENTS 102,914 1/ 1938Australia. 994,491 8/ 1951 France.

RICHARD B. WILKINSON, Primary Examiner.

STEPHEN J. TOMSKY, Examiner.

R. S. WARD, Assistant Examiner.

22. IN AN INSULATING AND ACOUSTICAL PANEL STRUCTURE, THE COMBINATIONCOMPRISING A HOLLOW BODY OF MATERIAL INCLUDING A TOP WALL, BOTTOM WALLAND PERIPHERAL SIDE WALLS CONNECTING THE TOP AND BOTTOM WALLS, SAID TOPWALL BEING GENERALLY RECTANGULAR AND HAVING A PLURALITY OF DEPRESSIONSMOLDED THEREIN AT THE CORNERS OF SAID RECTANGLE FOR RECEIVING ADHESIVEWHEREBY THE PANEL CAN BE ATTACHED TO A CEILING OR WALL, A LAYER OFINSULATING MATERIAL FASTENED TO THE INNER SURFACE OF THE TOP WALL, SAIDBOTTOM WALL BEING PERFORATED.